Masonry simulating roll siding and process of producing same



9 c. STOLP, JR 2,569,543 MASONRY SIMULATING ROLL SIDING AND PROCESS OF PRODUCING SAME Filed June 5, 1948 mmv .6 mu

7 INVENTOR Patented Oct. 2, 1951 MASONRY 'SIMULATINGZROLL. SIDING AND PROCESS ORPRODUCING SAME ,Charles Stolp, Jr., Chicago, 111., assignorto-Allied Chemical & Dye Corporation, NewYork,'N. Y., "a corporation of New York Application 111111615, 1948, Scrial-,N0..31,344

'-5-Claims.

1 This inventionrelates to roll siding having a stone wallsimulatinglappearance, i. e., the .appearance ofa wallmadejby laying different sizes ofhstones or other masonry elements bonded with mortar, ,and also to a ,novel;process of producing such ,roll siding.

In the vbuilding trade ,itjis .the practice in the construction of less expensive ;homes and other buildings to apply r oll siding having a surface appearance resembling rows of brick or stone to the studding .or jframework "forming the side walls of such buildings. :Such roll siding con- .sists of long strips of felt saturated and coated with water-proofing material, such as asphaltor other bitumen, surfaced with wear-resistant granulanmaterial, such 'as :crushed slate or other roofing granules and embossed "to produce the desired surface appearance. Roll siding of this type is transported and shipped in the form of rolls which need 'only be unrolled and cut to form strips of any desired length for application with approximately a 1 or 2" lap between contiguous rows of "strips, and hence is substantially less expensive to manufacture and apply than individual siding units. In fact the roll type siding represents for all practicalpurposes the least costly type-of siding now used in any substantial quantity inthe building industry.

Such siding is commonly produced in a conventional roofing-"machine modified to employan embossing cylinder -to provide the desired surface appearance on the finis'hedproduct. In this way the capacity of the roofingmachine'is utilized =most "efliciently and the cost of producing the siding is reduced in that the expense of having a separate installation involving relatively costly saturating, coating, surfacing, 'calendering, cut- :ting, embossing and winding-equipment i v elimi- 'nated.

Walls produced from .rollsiding, particularly of :the :stone simulating type, as heretofore made, have a monotonous appearance in that each strip of siding as applied repeats the :pattern of a preceding -or underlying strip. Chiefiy because the expenseinvolved the production of this type of siding is an extremely important factor in determining its saleability, it has not been found 'feasible to employtwo separate embossing cylinders each producing a different stone simulating pattern, since this would either involve the use .of duplicate saturating, coating, surfacing, cutting, embossing and winding equipment with consequent increased production costs, or the labor and los of capacity-involved iii-stopping the manufacturing operation while substituting one embossing. cylinder for the other. ,Furthenithe use oftwo difierentembossing cylinders would'en tail the expense and trouble of keeping separate stocks of the two types of roll siding thus made and of shipping to the place'of application the proper quantity of each to produce a wall construction having the desired stone simulating appearance.

Among the objects 'of-this invention is to provide aprocess of producing roll type siding which can becarried out in-conventional and existing roofingequipment, except for the addition of an embossing cylinder, 'toproduce the desired surface appearance and which, notwithstanding onlyone embossing cylinder is employed, results in the simultaneous productionof a plurality-of strips each 'having the appearance of a different arrangemerit of stones'of varioussizes, whichstrips may be applied to a wall' to produce a pleasing stone simulating appearance.

Another-object is to provide siding in roll form which when unrolled and applied produces a wall having an appearance of I being made from stones of 1 different sizes bonded :by mortar, the number of different stone simulating areasbeingsuchthat the :wall has .a pleasing appearance free from monotonous pattern' repetition.

Other objects and advantages of this invention .will :beapparent from the following detailed 'description thereof.

Inaccordance'withthis' invention a'felt oriother .fibrous :base is saturated and :coated with waterproofing materiaLsuchtas' asphalt or other bitumen, "andssurfaced with granular material as "is conventionalroofingand siding practice, andzthen passed into operative rcontact with an embossing cylinder which has along its length at least two distinct :stone simulating :patterns so that there is formed across the width Of the web at least two differentpatternswhich arerepeated atregular intervals alongthe length of the web as the embossing :cylinder i :rotated in :operative contact with-the movingweb. The web is partially or completely separated along the longitudinal meeting lines of the different patterns and without bodily separating the resultant strips, each having adi'fierent pattern thereon, wound into a roll to form-the desired roll siding product, the web being cut transversely to produce rolls containing the desired length ofgsiding. The partial or com plete separation of the web-along the longitudinal ;m'eeting:1ines of "the diflerent patterns desirably follows the embossing operation.

When it *is desired to apply the siding, it is unrolled. If only partially separated along the aforesaid longitudinal meeting lines the separation is completed prior to or immediately after the unrolling. The unrolled strips are applied to form the wall preferably so that two or more strips, each having a different stone simulating pattern,are applied one above the other with the desired lap, say 1 /2" between contiguous strips. By applying siding strips in succeeding rows having different stone simulating configurations, a wall is produced having the pleasing appearance of being made up of a relatively large number of stones of different sizes laid at random.

In the accompanying drawing Figure 1 is a side elevation somewhat diagrammatic in character and shows the steps involved in the manufacture of the roll siding of this invention;

Figure 2 is a fragmentary plan view of roll siding embodying the invention showing the full width of the siding as embossed and prior to winding to form the desired roll producty Figure 3 is a fragmentary plan view of two overlap ing strips corresponding to those shown in Figure 2 as applied in the intended manner to form a wall covering; and

Figure 4 is a fragmentary vertical section taken in a plane passing through line 4-4 of Figure 3.

Referring to the drawing with particular reference to Figure 1, a web of fibrous material It], which may be and preferably is the usual roofing felt made from fibrous material, as well known in this art, is fed by feed rolls H from the usual felt making machine or from a felt roll into a looping device |2. From the looping device |2 rolls |3 feed the web into any customary type of saturating equipment I4. saturating tank l5 may contain suitable water-proof saturant, such as asphalt or other bituminous material utilized for the impregnation and saturation of the felt.

Rolls I6 and I! feed the saturated web to a second looping device l8. The passage of the saturated web through the looping device l8 gives the saturant the necessary opportunity to dry and thoroughly impregnate the fibrous web. Rolls l9 and 20 feed the saturated web from the looping device Is to the coating equipment 2|. Rolls '20 are preferably driven at a slightly greater peripheral speed than that of the coating rolls 22,

23, the slack accumulating between driving rolls 2!) and guide roll 24 over which the web passes before entering the bight of the coating rolls 22,

23. Coating roll 23 is rotatably mounted in a tank 25. This tank may contain suitable waterproofing material, such as asphalt or other bituminous material employed for coating roofing and siding.

One side of web It) is completely coated by roll 23. Coating material is applied to the top of the web by means of a pipe 26 equipped with a discharge spout of a width approximately equal to that of the web. The coating material thus applied is spread uniformly over both sides of the web as it passes between the coating rolls Immediately upon leaving the coating equipment 2| and while the coating material is still tacky, the coated web passes under a pair of scrapers 21, each approximately 1 wide, disposed to contact the marginal areas of the web and remove substantially all of the coating material along a 1 /2" width band disposed at the marginal edges. The selvedge edges 28, 29 of ;reduced thickness as compared with the thickness ,of the remainder of the web are thus produced.

The web then passes under hopper 30 containing granular surfacing material, preferably gray or other colored granules which impart to the surface of the web an appearance resembling that of stone. These granules are showered by means of the usual distributing roll 3| on to the web therebeneath. The thus surfaced web then passes about reversing roll 32, which functions to partially embed the granular material in the underlying plastic coating. In the continued passage of the surfaced web, it comes under the hopper 33. Mica dust, talc or other material capable of rendering the back of the web non-cementitious is deposited in hopper 33 and discharged therefrom by distributing roll 34. The tale covered web then passes over a reversing roll 35 which imparts a smooth surface to the back of the web.

From the press rolls 36 the surfaced web passes through embossing equipment 31 consisting of a heated embossing cylinder 38 and a cooperating platen cylinder 39. The embossing cylinder 38 will be hereinafter described in greater detail. The web then passes through a slitting or scoring mechanism 40 for completely or partially severing the web into longitudinal contiguous strips, each as hereinafter more fully described, bearing a stone simulating pattern consisting of stones of different sizes at regularly occurring in tervals. The resultant web or series of contiguous strips then passes through a transverse cutting mechanism 4| of any conventional type which severs the same into predetermined lengths which are wound by the winding mechanism 42 to form a roll 43. From the winding mechanism 42 the rolls 43, as conventional, are wrapped for storage or transportation to the point of application.

The embossing cylinder 38 is provided with raised portions disposed circumferentially about the cylinder and also disposed on the periphery of the cylinder to produce the mortar simulating areas or lines 44 which desirably are each approximately wide, and the closely spaced parallel lines 41 each desirably 6" wide. Each revolution of the embossing cylinder 38 produces a series of mortar lines defining a plurality of masonry simulating areas of different dimensions hereinafter more fully described.

In the embodiment of the invention shown in Figure 2 each revolution of the cylinder produces a row of stone simulating areas 48, 49, 50 and 5|, hereinafter referred to as a marginal row of stone simulating areas. The top edge of areas 48, 49, 5|) and 5| is defined by the longitudinally extending mortar line 44a contiguous to selvedge edge 28. It is important to note that this marginal row consists of alternately long and short stone simulating areas; areas 48 and 50 are relatively long areas with area 50 being somewhat longer than area 48, and areas 49 and 5| are the relatively short stone simulating areas, with area 5| being longer than area 49. Suitable dimensions for these areas are as follows: 4812%" x 3%"; 49-7% X 3 50-13%" x 6 5|-8%" x 3 Along the marginal edge of the web contiguous to selvedge edge 29 a second marginal. row of stone simulating areas 52, 53, 54 and 55 is produced. These areas are alternately long and short and are dimensioned as follows: 52-12 A;" x 3%"; 53-7% x 3%"; 54-13%" x 6 and 55-8% x 3 thus areas 48, 49, 50 and 5| are identical, respectively, with areas 52, 53, 54 and 55. There is also simultaneously produced interior stone simulating areas indidiffer from the areas 64, 65,. 66, 61, 68"and 6E] constituting an interior group of six stone-simulating areas disposed on the upper half of the web. Suitable-dimensions for the areas 56 to 60, inclusive, are as follows: 56-13" x 516 x 2"; 58-base side (viewing Figure 2) 15 top side 13 right side 7%" and length of left vertical portion 2 59--base 3%", left side 4%", top side 5%; 60-10%" x 2%. Suitable dimensions for the areas 64 to 65, inclusive, are as follows: IN-9V x 2"; 6516" x 5 4"; 66-8 x 7% 61- 7%," x 4%"; [SS-3% x 2%"; and 69 -10 4; x2%". Interior areas GI, 62 and 63 are desirably of the following dimensions: til-14%" x 8 4"; 62-41" x 8%"; and 6316 x 13". These areas are scored or slid along longitudinal line 12 bisecting areas GI, 62 and 63 and forming areas Bid and 6th, desirably each 14%" x 4 62a, 621) each 11" x 4 and 63a, 63b each 16 x 6 The space between the parallel dot-and-dash lines Ill, H on Figure 2 of the drawing indicates the area of the Web ID embossed during each complete revolution of the embossing cylinder 38. The" web is fed at a constant rate of speed correlated with the speed of rotation of the embossing cylinder so as to feed the same linear distance of web through the embossing equipment per revolution of the embossing cylinder 38 and thereby produce across thewidth of the web the pattern shown in Figure 2 within the confines of the lines 10, ll. This pattern, as indicated in this figure, is repeated on each succeeding portion of the width of the Web, which portion corresponds in area to that between the lines 16, II as the succeeding portion is brought into contact with the rotating cylinder. The web is then severed or scored along, its-longitudinal center line 12 and, without separating the two strips 13, 14 thusproduced, is woundinto a roll to produce the desired roll siding containing the two contiguous sections I3 and 14 in edge abutting relationship.

The resultin siding, as shown in Figure-4, consists of a felt base 15 having coating layers 16, 1? on opposite sides, a layer of antistick material 18 on the back and a layer 190i granular'material' partially embedded in the coating layer 16. The thickness of coating layer 16 in Figure 4 is exaggerated to show relative depths of lines '41 simulating rough texture stone and mortar lines M. The face of the web is embossed to'produce (1) two marginal rows, one consisting of alternating long and short stone simulating areas 58, 49, 56 and 5| and the other ofalternately long and short areas 52, 53-, 54 and 55; areas 48', 49, 50 and 51 are identical, respectively, with areas 52, 53, 54 and 55; (2) a group of. interior stone simulating areas 55 to 60, inclusive, on the lower half of the web; (3) a second group of interior stone simulating areas 64 to 69, inclusive, on the upper half, which groups diifer from each other in the arrangement of stone simulating areas; and (4) an interior row of areas 61, 6 2 and 63 through each of which passes the longitudinal median line 12 of the web. Thus when the web is separated into two strips T3, 14, the former has along its marginal edge Tl stone simulating areas-Eta, 52a and 63a and the latter has along its marginal edge 80 stone simulating areas Blb, 62b and 63b,

areas Bla; 62a and 63a being identical, respectively, with areas Gib, 62b and 631).

When the roll siding is applied it is unrolled and divided into the two strips 13, 14. All the strips are applied to form the Wall with the selved'ge edge 28, 29, as the case may be, at the top. Strip 14' may firstbe appliedby nailing or otherwise to the wall. The succeeding or overlying strip on the wall desirably is a strip 13, thereafter a strip 14 is applied to the underlying 13 strip, etc. Before application, each strip 74' is turned so that the selvedge edge 29 appears at the top of the strip. By so turning the strip T4 the relative position of areas 52 to is reversed as compared with their position shown in Figure 2. Thus in Figure 2 showing the position of these areas as produced, area 55 is positioned to'the left of. area 58; in Figure 3 which shows the position of these areas when the strips are applied, area 59 is positioned to the right of area 58. Hence, the identical stone simulating areas49 and 53,. and 5! and 55, when the strips are laid; no longer occur longitudinally opposite each other as in Figure 2 but bear the relative positions shown in Figure 3. Likewise the stone simulating areas 61b, 62b and 531) on strip 14, which when. out run from right to left (see Figure. 2), when the strip is turned for application are disposed so that they run from left to right.

The siding may be laid as shown in Figure 3 to produce a wall having the pleasingappearance of beingmade from a large number of different sizes of stone laid at random. Due to the turning of strip 14 in order to have the selvedge edge 29 on top, a staggering of most of the vertical mortar simulating areas throughout the Wall results even though. the applicator, when placing a succeeding strip, positions it so that one mortar line of one strip is in vertical alignment with a mortar lined the immediately underlying strip. Thus, as isevident from Figure 3, the mortar line between areas lila and 62a is in vertical alignment with that between areas 54 and 55; the mortar lines between 5|a. and 63a, between 63a and 62a and between 6111 and 6300 are staggered relative tothose between 52 and 53; 53 and 54 and 55 and 52. By aligning one or more mortar lines in a vertical direction, as in the case of the mortar lines between 5 la and 62a and. 54 and 55, the long longitudinal mortar line 44a, or 44b between adjoining strips 13 and 14 appears to be broken where the vertically aligned mortar lines appear. The di-fierent pattern of stone simulating areas 56 toiiO of strip 14 as compared with stone simulating. areas 64 to 69 of strip 13 and the diiferent sizes of stone simulating areas 65a, 52a and 63a, which as strips 13 are laid run from right to left, and areas 6 I (2,621) and 531), which are of the same size, respectively, as areas 6m, 62a and 63a but as strips 14 are laid run from left to right, greatly enhances the pleasing appearance of the Wall andlthev impression that the wall is composed of a multiplicity of stones of different sizes laid at random,

While the drawing shows the production of a web which is divided along its longitudinal median. line i-ntotwo strips, each having a desired stone. simulating pattern. thereon, it will be understood that the embossing cylinder may be so designed as to produce three or more such siding strips which. are wound: into a single roll after partial or complete severance along the meeting lines of the separate strips. If desired, the web embossed, as shown, for example, in Figure 2, may be wound on a roll without partially or completely severing the web along the longitudinal meeting lines of the strips each having different stone simulating patterns thereon, the roll being provided with indicia indicating the point at which it should be cut to produce strips each having a different pattern. Thus, for example, the last convolution of the roll may have a line thereon indicating where the roll should be cut. In a broad sense, of course, score or perforation lines on the web are indicia on the roll indicating Where the web or roll should be cut to produce the separate strips.

It will be noted this invention provides a, process of producing roll type siding which can be carried out in conventional roofing equipment, except for the addition of a singl embossing cylinder of the type hereinabove described. It will be further noted notwithstanding only a single embossing cylinder is employed in the practice of this invention, there is simultaneously produced a plurality of siding webs each having the appearance of a different arrangement of stones of various sizes separated by mortar joints. Hence, it is only necessary to stock and ship this one type of roll siding which when applied as hereinabove described results in a wall having the pleasing appearance of being made from a large number of different sizes of stone laid at random and bonded by mortar, which wall is free of monotonous pattern repetitions. While not preferred, if desired, the two strips 13, 14, each having a different pattern, may be applied 50 that strips 13 only are applied to one wall and strips 14 to another wall.

In the claims where reference is made to cutting said web, it is intended to include a slitting or cutting operation which cuts the Web completely through the full thickness thereof, as well as a partial severance, for example, perforating the web or scoring it so that the web may readily be separated into strips when it is unwound from the roll or even While on the roll.

Since certain changes in carrying out the above process, and certain modifications in the article which embody the invention may be made without departing from its scope, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.

What is claimed is:

1. In a process for continuously producing masonry simulating roll siding which process comprises impregnating a felt web with a bituminous saturant, applying a bituminous coating layer to the impregnated web, and surfacing the coated web with granular surfacing material, the improvement which comprises embossing the granular material surface of said web to produce across substantially the full width of said web at least two different masonry simulating patterns, each of said patterns being repeated in contiguous relationship along the length of said web and consisting of different masonry simulating areas separated by mortar line simulating areas, cutting said web along each longitudinal line separating the different patterns to form contiguous strips having said different patterns thereon respectively and winding said strips to form rolls of siding each roll containing at least two of said strips having said different patterns thereon respectively in side by side relationship on said roll.

2. In a process for continuously producing masonry simulating roll siding which process comprises impregnating a felt web with a bituminous saturant, applying a bituminous coating layer to the impregnated web, forming selvedge edges along the opposite longitudinal edges of the coated web and surfacing the coated web with granular surfacing material, the improvement which comprises embossing the granular material surface of said web to produce across substantially the entire width of said web between said selvedge edges two diffrent masonry simulating patterns, each of said patterns being repeated in contiguous relationship along the length of said web and consisting of different masonry simulating areas separated by mortar line simulating areas, cutting said web along its longitudinal median line to form two contiguous strips having said different patterns thereon respectively and winding said strips to form rolls of siding each roll containing both of said strips in side by side relationship on said roll.

3. Roll siding consisting of a web having a wear-resisting surface in which is embossed across the width of said web at least two different stone simulating patterns, each of said patterns being repeated in contiguous relationship along the length of said web and consisting of different sizes and shapes of stone simulating areas separated by mortar joint simulating areas, said roll siding having thereon indicia indicating a longitudinally extending line separating said web into strips, each of which strips has a diff rent stone simulating pattern thereon from that on a contiguous strip.

4. Roll siding consisting of a web having a wear-resisting surface in which is embossed across the width of said web two different stone simulating patterns, each of said patterns being repeated in contiguous relationship along the length of said web and consisting of different sizes and shapes of stone simulating areas separated by mortar joint simulating areas, said roll siding having thereon indicia indicating a longitudinally extending line separating said web into two strips each having a different stone simulating pattern thereon.

5. Roll siding consisting of a pair of contiguous strips both wound in side-by-side relationship with their contiguous marginal edges in abutting relationship to produce said roll, each strip consisting of a felt base, saturated and coated with water-proofing material, surfaced with granular material and embossed to embed the granular surfacing into the underlying coating to produce a stone simulating pattern consisting of stone simulating areas of different dimensions separated by mortar joint simulating areas, said patterns being repeated in contiguous relationship along the length of said strip, the pattern on one of said strips being different from that on the other of said strips.

CHAS. STOLP, J R.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,036,427 Bird Aug. 20, 1912 1,968,535 Moone July 31, 1934 1,972,810 Wettlaufer Sept. 4, 1934 2,047,741 Miller July 14, 1936 2,218,791 Herscovitz Oct. 22, 1940 

1. IN A PROCESS FOR CONTINUOUSLY PRODUCING MASONRY SIMULATING ROLL SIDING WHICH PROCESS COMPRISES IMPREGNATING A FELT WEB WITH A BITUMINOUS SATURANT, APPLYING A BITUMINOUS COATING LAYER TO THE IMPREGNATED WEB, AND SURFACING THE COATED WEB WITH GRANULAR SURFACING MATERIAL, THE IMPROVEMENT WHICH COMPRISES EMBOSSING THE GRANULAR MATERIAL SURFACE OF SAID WEB TO PRODUCE ACROSS SUBSTANTIALLY THE FULL WIDTH OF SAID WEB AT LEAST TWO DIFFERENT MANSONRY SIMULATING PATTERNS, EACH OF SAID PATTERNS BEING REPEATED IN CONTIGUOUS RELATIONSHIP ALONG THE LENGTH OF SAID WEB AND CONSISTING OF DIFFERENT MASONRY SIMULATING AREAS SEPARATED BY MORTAR LINE SIMULATING AREAS, CUTTING SAID WEB ALONG EACH LONGITUDINAL LINE SEPARATING THE DIFFERENT PATTERNS TO FORM CONTIGUOUS STRIPS HAVING SAID DIFFERENT PATTERNS THEREON RESPECTIVELY AND WINDING SAID STRIPS TO FROM ROLLS OF SIDING EACH ROLL CONTAINING AT LEAST TWO OF SAID STRIPS HAVING SAID DIFFERENT PATTERNS THEREON RESPECTIVELY IN SIDE BY SIDE RELATIONSHIP ON SAID ROLL. 